Structural instrument panel carrier assembly

ABSTRACT

A motor vehicle body has an instrument panel construction that includes a structural instrument panel carrier of plastic material for mounting instrument panel components. The carrier is attached to side pillars located at a juncture of passenger and engine compartments so as to form a cross beam. The instrument panel construction has its external appearance determined by adding facial instrument panel coverings to the instrument panel carrier after the instrument panel components are mounted on the instrument panel carrier. The structural instrument panel carrier may also be integrated with a front of dash (FOD) panel that may be composed of the same material and that provides a second cross beam.

This is a divisional of application Ser. No. 08/078,140, filed on Jun.15, 1993, now U.S. Pat. No. 5,364,159.

BACKGROUND OF THE INVENTION

This invention relates to an instrument panel construction for a vehiclebody and more particularly to an instrument panel construction that hasan instrument panel carrier that serves as a structural component of thevehicle body.

Motor vehicle bodies customarily include a frame or underbody that has apair of vertical stantions or A-pillars on the opposite sides of thevehicle body at the juncture of the engine compartment and the passengercompartment. These stantions or A-pillars are connected to each other bya cross beam at the cowl of the vehicle body. See, for example U.S. Pat.No. 4,391,465 granted to Renzo Piano Jul. 5, 1983 which discloses a bodystructure that has side stantions that are connected to each other bytwo cross beams, one of which is at the cowl of the vehicle in thevicinity of the instrument panel.

Instrument panel constructions that include structural components thatact as a cross beam connecting the stantions or A-pillars of the vehiclebody are also known. For example U.S. Pat. No. 4,733,739 granted toSiegfried Lorenz, Erich Altdorf and Hans Vogt Mar. 29, 1988 discloses ascuttle-dash instrument panel component comprising a central supportpart 2 of a rigid polyurethane foam material fibre-reinforced from a matof continuous fibers and a second lower support part 3 likewise offibre-reinforced rigid polyurethane foam material. The central supportpart 2 and the lower support part 3 are securely joined together alongtheir approximately horizontal junction plane by a thin-film adhesive 7so as to produce a rigid box-like transverse support which cooperates inforce-transmitting manner with the bodywork structure by way of lateralflanges 8 and 9 at the junction plane. However, this rigid box-liketransverse support has several drawbacks. The support parts 2 and 3 aremolded in very complex shapes to absorb all the necessary ventilatingand heating or air-conditioning units in a fully integrated form.Consequently load sharing is difficult and the parts are expensive tomanufacture. Furthermore these complex molded plastic parts 2 and 3 mustbe joined together in a precise manner which adds further to themanufacturing expense. Moreover the load is transferred to thetransverse support by way of lateral flanges at the junction plane ofthe two parts which concentrates the load at the flanges and increasesthe stress in these parts in and near the flanges. Another drawback isthat the lower support part determines the interior styling in largepart.

U.S. Pat. No. 4,759,568 granted to Franz Paefgen and Hermann Guhl Jul.26, 1988 discloses an instrument panel construction for a motor car thatincludes a light alloy beam 1 which extends over the whole width of thevehicle compartment below the windshield and which carries an instrumenttop 2. This construction avoids at least some of the problems associatedwith the two-piece molded plastic construction discussed above. However,the light alloy beam 1 determines the interior styling in large part andit does not have any provision for holding several components associatedwith instrument panels, such as heating and ventilating or airconditioning units and controls, glove boxes, radios and knee bolsters.

U.S. Pat. No. 5,088,571 granted to Donald R. Burry and Leonard J. PilatoFeb. 18, 1992 discloses a modular structural instrument panel carriercomprising panels 28 and 40 that are attached together to define a boxbeam assembly 54 which extends transversely across the vehicle. Thepanels 28 and 40 are preferably constructed of fiber reinforced plastic.This structure has many of the drawbacks that are associated with U.S.Pat. No. 4,733,739 granted to Siegfried Lorenz, Erich Altdorf and HansVogt Mar. 29, 1988 that is discussed above. Namely, the box beamassembly 54 consists of two complex molded plastic parts 28 and 40 thatmust be joined together in a precise manner which causes load sharingproblems and expense. Moreover the load is transferred solely to thepart 28 which concentrates the load and increases the stress in thisparts. Furthermore panels 28 and 40 do not have any provision forholding instrument panel components such as bolster pads and wiringducts.

SUMMARY OF THE INVENTION

The object of this invention is to provide an instrument panelconstruction that has a structural instrument panel carrier that acts asa cross beam for connecting the side stantions or A-pillars to eachother at or near the cowl of the vehicle body and that avoids one ormore of the drawbacks that are enumerated above.

A feature of the instrument panel construction of the invention is thatit has a structural instrument panel carrier of one piece plasticconstruction which is less expensive to manufacture than plastic boxbeams of two piece construction or light alloy beams.

Another feature of the instrument panel construction of the invention isthat it has a structural instrument panel carrier of one piece plasticconstruction that has conformations that strengthen the carrier andprovide support for various instrument panel components.

Another feature of the instrument panel construction of the invention isthat it has a structural instrument panel carrier of one piece plasticconstruction that has a lower panel for supporting knee bolsters andwiring ducts.

Another feature of the instrument panel construction of the invention isthat the structural instrument panel carrier is universal in nature inthat it provides a backbone for an instrument panel that can be tailoredfor a variety of vehicle styles simply by changing facial instrumentpanel coverings.

Another feature of the instrument panel construction of the invention isthat the structural instrument panel carrier is adapted to supportinstrument panel components, including air distribution ducts and gloveboxes.

Another feature of the instrument panel construction of the invention isthat the instrument panel construction has a structural instrument panelcarrier that acts as a cross beam and that is adapted to support avariety of facial instrument panel coverings for changing interiordesigns and styles.

Still another feature of the instrument panel construction of theinvention is that the instrument panel construction has a structuralinstrument panel carrier that acts as a cross beam for controllingenergy management as well as supports styling driven instrument panelcomponents such as air distribution ducts, gloveboxes, and air bagcanisters.

Still yet another feature of the instrument panel construction accordingto another aspect of the invention is that the instrument panelconstruction has a structural instrument panel carrier that can beintegrated with a front-of-dash (FOD) panel composed of the samematerial. This aspect of the invention incorporates the structuralfunctions currently and conventionally provided by the an FOD panel,cowl and steel cross beam and the functions of the structural instrumentpanel carrier into a single composite plastic member.

Still another feature of this aspect of the invention is that theintegrated design provides two cross beams connecting the side stantionsor A-pillars in the vicinity of the cowl, namely that of the structuralinstrument panel carrier and that of the FOD panel.

Still yet another feature of the instrument panel construction accordingto yet another aspect of the invention is that the instrument panelconstruction has a structural instrument panel carrier that not onlyacts as a cross car beam for connecting the side stantions or sidepillars to each other but also has ductwork integrated into it.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the inventionwill become more apparent from the following description taken inconjunction with the accompanying drawings wherein like references referto like parts and wherein:

FIG. 1 is a perspective view of a vehicle body having an instrumentpanel construction in accordance with the invention;

FIG. 2 is a cross section of the structural instrument panelconstruction shown in FIG. 1;

FIG. 3 is a cross section of an instrument panel construction inaccordance with a second embodiment of the invention;

FIG. 4 is a cross sectional of an instrument panel construction inaccordance with a third embodiment of the invention; and

FIG. 5 is a cross section of an instrument panel construction inaccordance with a fourth embodiment of the invention.

DESCRIPTION OF THE INVENTION

Referring now to the drawing, FIG. 1 shows a motor vehicle body 10 thathas an instrument panel construction 12 that includes a structuralinstrument panel carrier 14 in accordance with the invention. Thestructural instrument panel carrier 14 mounts instrument panelcomponents in the motor vehicle body 10 between the side stantions orA-pillars 16. These A-pillars are located at a juncture of passenger andengine compartments and typically carry hinges for supporting swingingfront vehicle doors.

The A-pillars 16 are typically connected by a cross beam at the cowl,and in this case, the structural instrument panel carrier 14 serves as across car beam that is connected to the A-pillars at its ends toreinforce the vehicle body and increase its torsional rigidity. Thestructural instrument panel carrier 14 is molded as one piece of strongthermoplastic material, preferably a fiber filled thermoplastic materialsuch as urethane filled with fiberglass. It may be produced using knownstructural reaction injection molding (SRIM) technology, or it may beanother plastic or metal/plastic hybrid construction material havingsimilar rigid properties.

The structural carrier 14 has upper and lower generally vertical backpanels 18 and 20 that extend transversely across the motor vehicle bodyfor attachment to the A-pillars 16 and a generally horizontal shelfpanel 22. The shelf panel 22 interconnects the upper and lower backpanels 18, 20 and projects rearwardly of the back panels toward thepassenger compartment for supporting instrument panel components asexplained below.

The upper back panel 18 has a central opening 24 for a heating,ventilating, air conditioning ("HVAC") module 26 that includes a fan andinlet and outlet ducts for connection to an air distribution system. Thelower back panel 20 has an opening 28 for a steering column assembly 30that carries an instrument package 32. The steering column opening 28which is on the driver side of the vehicle is laterally spaced from thecentral opening 24 of the upper panel 18.

The shelf panel 22 and the lower back panel 20 each have a portion onthe passenger side of the vehicle that extends far enough to span thecentral opening 24 in the upper back panel 18 and preferably extends allthe way to the steering column opening 28.

The structural carrier 14 also has two laterally spaced vertical walls34 at the sides of the central opening 24 in the upper back panel 18that are integrally connected to respective edges of the upper backpanel 18 defining the central opening 28. The vertical walls 34 projectrearwardly of the upper back panel 18 with their bottom edges beingintegrally connected to the shelf panel 22 that spans the centralopening 24. The laterally spaced vertical walls 34 provide a compartmentfor a portion of the HVAC module 26 and increase the torsional rigidityand bending strength of the one-piece structural carrier 14.

The upper back panel 18 comprises an upper section 36 and a lowersection 38 that are interconnected by a rib 40 that projects rearwardlyof the sections 36 and 38 to support instrument panel components thatface the passenger compartment, such as air bag module 42 and to supportother instrument panel components, such as glove box 44 in cooperationwith the shelf panel 22. The rib 40 has portions on either side of thecentral opening 28 that are integrally connected to the vertical walls34 respectively.

The structural instrument panel carrier 14 also preferably includes asecond pair of vertical walls 41 that are integrally connected to thelower section 38, the rib 40 and the shelf panel 22 at the respectiveoutboard ends of the panel carrier 14 to increase its strength.

The upper section 36 of the upper back panel 18 has a second rib 46 thatprojects forwardly of the upper section 36 toward the enginecompartment. The second rib 46 supports air ducts 47 on either side ofthe central opening 24 as shown in FIG. 2. The air ducts 47 areconnected to an air outlet of the HVAC module 26 when it is assembled tothe carrier 14 by suitable manifolding that may be a part of the airducts 47 or HVAC module 26. The air ducts 47 distribute air to thepassenger compartment via sleeves 48 that are fitted in a plurality ofair passages 50 that extend through the upper section 36.

The structural instrument panel carrier 14 further comprises a shortshelf 52 that is connected the vertical walls 34 above the shelf panel22 to provide a compartment for an instrument panel component, such asradio 54. The shelf 52 itself also provides support for an instrumentpanel component such as an HVAC control module 56.

The lower back panel 20 has a plurality of integrally attached fins 58that project forwardly toward the engine compartment beneath the shelfpanel 22 to support wiring ducts 59.

The structural instrument panel carrier 14 is the "backbone" of theinstrument panel construction 12 that has its external appearancedetermined by adding facial instrument panel coverings as shown in FIG.2 in phantom. These include a topper pad 60, glovebox door 62, lowerknee bolsters 64 that may be attached to the lower vertical back panel20 and other surface items as shown in phantom in FIG. 2.

The entire instrument panel construction of this embodiment can beassembled off-line as a modular instrument panel construction andinstalled through the windshield opening.

Another embodiment of the invention is shown in FIG. 3. Here theinstrument panel construction 112 has a structural instrument panelcarrier 114 that is integrated with a front-of-dash (FOD) panel 116 thatis composed of the same thermoplastic material, preferably a fiberfilled thermoplastic material such as urethane filled with fiberglass.Each part may be produced using known SRIM technology.

The instrument panel construction 112 incorporates the structuralfunctions currently and conventionally provided by the FOD panel, cowland steel cross beam in addition to the functions of the structuralinstrument panel carrier 14 that is disclosed above and described inconnection with FIGS. 1 and 2. The integrated design of the instrumentpanel construction 112 provides two cross beams connecting the sidestantions or A-pillars of the vehicle body in the vicinity of the cowl,namely that of the structural instrument panel carrier 114 itself andthat of the FOD panel 116.

The structural instrument panel support 114 and the FOD panel 116 aremolded separately and tied together adhesively via pluralities ofrespective integral mating ribs 118 and 120 that space the panels 114and 116 longitudinally. These vertical and horizontal ribs form passagesand compartments for wiring harnesses, air ducts, HVAC unit, gloveboxand other instrument panel components.

The instrument panel construction 112 integrates instrument panelcarrier 114 and FOD panel 116 in a composite molding of two or moreparts using a known process such as SRIM.

This composite molding is also the "backbone" of an instrument panelconstruction 112 that is completed by adding topper pad, glovebox doorand other interior surface items as shown in phantom in FIG. 3.

The entire instrument panel construction of this embodiment likewise canbe assembled off-line as a modular instrument panel assembly andinstalled through the windshield opening.

Yet another embodiment of the invention is shown in FIG. 4. Here theinstrument panel construction 212 has a structural instrument panelcarrier 214 that not only acts as a cross car beam for connecting theside stantions or side pillars to each other but also has ductworkintegrated into it. More specifically the instrument panel carrier 214includes a cross car portion 216 of U-shaped cross section that forms anopen channel or three sides of a duct 218. The channel is closed by afourth side that is provided by a duct closeout panel 220 of rigidthermoplastic material that can be formed by extrusion, vacuum formingor injection molding.

The instrument panel carrier 214 has recessed flanges 222 at thetransverse or cross car edges of the opening of the cross car portion216 and transverse grooves 224 that are spaced outwardly of the recessedflanges 222. The transverse grooves 224 have tapered side walls.

The duct close out panel 220 has two elastomeric thermoplastic sealingstrips 226 that may be co-molded with the duct close out panel 22. Thesesealing strips 226 biasingly engage the recessed flanges 222 to seal theduct 218 when the duct close out panel 222 is attached to the instrumentpanel carrier 214.

The duct close out panel 220 is attached to the instrument panel carrier214 by ribs 228 at the transverse edges of the duct close out panel 220that are bonded in the transverse grooves 224. The ribs 228 are taperedso that the ribs 228 center themselves in the transverse grooves 224 andcoat both tapered side walls of the transverse grooves 224 withadhesive.

Still yet another embodiment of the invention is shown in FIG. 5. Herethe instrument panel construction 312 has a structural instrument panelcarrier 314 that also has ductwork integrated into it as well as actingas a cross car beam for connecting the side stantions or side pillars toeach other.

The instrument panel carrier 314 also includes a cross car portion 316of U-shaped cross section that forms an open channel of a duct 318 thatis closed by a duct closeout panel 320 of rigid thermoplastic materialthat can be formed by extrusion, vacuum forming or injection molding.

The instrument panel carrier 314 also has recessed flanges 322 at thetransverse or cross car edges of the opening of the cross car portion316 and transverse grooves 324 that are spaced outwardly of the recessedflanges 322. The transverse grooves 324, however, are enlarged and holdthermoplastic inserts 325 that act as retainer clips.

The duct close out panel 320 also has two elastomeric thermoplasticsealing strips 326 that may be co-molded with the duct close out panel322 and that biasingly engage the recessed flanges 322 to seal the duct318 when the duct close out panel 322 is attached to the instrumentpanel carrier 314.

The duct close out panel 320 is attached to the instrument panel carrier314 by bulb shaped ribs 328 at the transverse edges of the duct closeout panel 320 that are snap fit into the thermoplastic inserts 325 thatare held in the transverse grooves 324 by dovetail connections in thebottoms of the grooves. As indicated above, the thermoplastic inserts325 act as retainer clips for the bulb shaped ribs 328.

The instrument panel constructions 212 and 312 incorporate ductworkstructure and functions in addition to the functions of the structuralinstrument panel carrier 14 that is disclosed above and described inconnection with FIGS. 1 and 2. In other words, these instrument panelconstructions may also be the "backbone" of an instrument panelconstruction that is completed by adding topper pad, glovebox door andother interior surface items. Moreover, these instrument panelconstructions can be also assembled off-line as a modular instrumentpanel assembly and installed through the windshield opening.

The invention has been described in an illustrative manner, and it is tobe understood that the terminology which has been used is intended to bein the nature of words of description rather than of limitation.

Obviously, many modifications and variations of the present invention inlight of the above teachings may be made. It is, therefore, to beunderstood that, within the scope of the appended claims, the inventionmay be practiced otherwise than as specifically described.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. An instrument panelconstruction comprising:a structural instrument panel carrier of onepiece plastic construction that extends transversely across a motor bodyfor attachment to side pillars located on opposite sides of the motorvehicle body so as to act as a cross beam connecting the side pillars,the instrument panel carrier having portions for supporting variousinstrument panel components and carrying a plurality of facialinstrument panel coverings for effecting the external appearance of theinstrument panel construction, the instrument panel construction havingduct work integrated into it including a cross car portion of U-shapedcross section that forms an open channel of a duct that is closed by aduct closeout panel that is attached to the instrument panel carrier,the instrument panel carrier having recessed flanges at transverse orcross car edges of an opening of the cross car portion and the ductclose out panel having seals that biasingly engage the recessed flangesto seal the duct when the duct close out panel is attached to theinstrument panel carrier, and the instrument panel carrier havingtransverse grooves that are spaced outwardly of the recessed flanges andthe duct close out panel being attached to the instrument panel carrierby ribs at the transverse edges of the duct close out panel that aredisposed in the transverse grooves.
 2. The instrument panel constructionas defined in claim 1 wherein the transverse grooves have tapered sidewalls and the ribs are bonded in the transverse grooves, the ribs beingtapered so that the ribs center themselves in the transverse grooves andcoat both tapered side walls of the transverse grooves with adhesive. 3.An instrument panel construction comprising:a structural instrumentpanel carrier of one piece plastic construction that extendstransversely across a motor vehicle body for attachment to side pillarslocated on opposite sides of the motor vehicle body so as to act as across beam connecting the side pillars, the instrument panel carrierhaving portions for supporting various instrument panel components andcarrying a plurality of facial instrument panel coverings for effectingthe external appearance of the instrument panel construction, theinstrument panel construction having duct work integrated into itincluding a cross car portion of U-shaped cross section that forms anopen channel of a duct that is closed by a duct closeout panel that isattached to the instrument panel carrier, the instrument panel carrierhaving recessed flanges at transverse or cross car edges of an openingof the cross car portion and the duct close out panel has twoelastomeric thermoplastic sealing strips that biasingly engage therecessed flanges to seal the duct when the duct close out panel isattached to the instrument panel carrier, the instrument panel carrierhaving transverse grooves that are spaced outwardly of the recessedflanges and the duct close out panel is attached to the instrument panelcarrier by ribs at the transverse edges of the duct close out panel thatare disposed in the transverse grooves, and the transverse groovesholding thermoplastic inserts that act as retainer clips and the ribsbeing bulb shaped and snap fit into the thermoplastic inserts that actas retainer clips for the bulb shaped ribs.
 4. An instrument panelconstruction comprising:a structural instrument panel carrier of onepiece plastic construction that extends transversely across a motorvehicle body for attachment to side pillars located on opposite sides ofthe motor vehicle body, the structural instrument panel carrier having aportion of U-shaped cross section that forms an open channel of a duct,a duct close-out panel attached to the instrument panel carrier to closethe open channel the instrument panel carrier having recessed flanges atopposite edges of the portion of U-shaped cross section and the ductclose out panel having seals that biasingly engage the recessed flangesto seal the duct when the duct close out panel is attached to theinstrument panel carrier, and the instrument panel carrier havinggrooves that are spaced outwardly of the recessed flanges and the ductclose out panel being attached to the instrument panel carrier by ribsat opposite edges of the duct close out panel that are disposed in thegrooves.
 5. The instrument panel construction as defined in claim 4wherein the grooves have tapered side walls and the ribs are bonded inthe grooves, the ribs being tapered so that the ribs center themselvesin the grooves and coat both tapered side walls of the grooves withadhesive.
 6. An instrument panel construction comprising:a structuralinstrument panel carrier of one piece plastic construction that extendstransversely across a motor vehicle body for attachment to side pillarslocated on opposite sides of the motor vehicle body, the structuralinstrument panel carrier having a portion of U-shaped cross section thatforms an open channel of a duct, a duct close-out panel attached to theinstrument panel carrier to close the open channel, the instrument panelcarrier having recessed flanges at opposite edges of the portion ofU-shaped cross section and the duct close out panel having seals thatbiasingly engage the recessed flanges to seal the duct when the ductclose out panel is attached to the instrument panel carrier, theinstrument panel carrier having grooves that are spaced outwardly of therecessed flanges and the duct close out panel being attached to theinstrument panel carrier by ribs at opposite edges of the duct close outpanel that are disposed in the grooves, and the grooves holdingthermoplastic inserts that act as retainer clips and the ribs being bulbshaped and snap fit into the thermoplastic inserts that act as retainerclips for the bulb shaped ribs.
 7. An instrument panel constructioncomprising:a structural instrument panel carrier of one piece plasticconstruction that extends transversely across a motor vehicle body forattachment to side pillars located on opposite sides of the motorvehicle body so as to act as a cross beam connecting the side pillars,the instrument panel carrier having portions for supporting variousinstrument panel components and carrying a plurality of facialinstrument panel coverings for effecting the external appearance of theinstrument panel construction, the instrument panel construction havingduct work integrated into it including a cross car portion of U-shapedcross section that forms an open channel of a duct that is closed by aduct closeout panel that is attached to the instrument panel carrier,the instrument panel carrier having flanges at transverse or cross caredges of an opening of the cross car portion that include transversegrooves and the duct close out panel being attached to the instrumentpanel carrier by ribs at the transverse edges of the duct close outpanel that are disposed in the transverse grooves, and the transversegrooves holding thermoplastic inserts that act as retainer clips and theribs being bulb shaped and snap fit into the thermoplastic inserts. 8.An instrument panel construction comprising:a structural instrumentpanel carrier of one piece plastic construction that extendstransversely across a motor vehicle body for attachment to side pillarslocated on opposite sides of the motor vehicle body, the structuralinstrument panel carrier having a portion of U-shaped cross section thatforms an open channel of a duct, a duct close-out panel attached to theinstrument panel carrier to close the open channel, the instrument panelcarrier having flanges at opposite edges of the portion of U-shapedcross section that include grooves holding thermoplastic inserts thatact as retainer clips, and the duct close out panel being attached tothe instrument panel carrier by bulb shaped ribs at opposite edges ofthe duct close out panel that are disposed in the grooves and fit intothe thermoplastic inserts.